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Bobcat 325 Excavator Service Manual (SN 511820001-511899999)

Format: PDF (Printable Document)

File Language: English

File Pages: 372

File Size: 10.68 MB (Speed Download Link)

Brand: Bobcat

Model: 325 Excavator

Book No: 6722849

Serial No: SN 511820001-511899999

Type of Document: Service Manual

Categories: ,

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Bobcat 325 Excavator Service Manual (SN 511820001-511899999)

A 325 mini excavator is a tight-space digging machine, good for trenching, footings, and utility work where a big hoe won't fit. The person who reaches for this service manual is the one actually tearing into the machine when it quits making you money. They're chasing hydraulic problems, electrical gremlins, or doing engine and swing motor work. This manual is what you use when guesswork starts getting expensive.

What this manual helps you do

  • Diagnose no-move, weak boom, or slow track issues by following hydraulic and hydrostatic test procedures
  • Trace and troubleshoot electrical problems using wiring diagrams and step-by-step checks with a meter
  • Check, adjust, and replace components in the travel motors, swing drive, and main control valve
  • Follow teardown and reassembly steps for the engine, cylinders, and major hydraulic components
  • Set and verify adjustments after repairs so pressures, linkages, and controls are back in spec

Who this is for

This is for someone working on a Bobcat 325 excavator with serial number between 511820001 and 511899999, who wants dealer-level repair info without dealer labor rates. If you just need to know how to run the machine or basic maintenance intervals, you want the operator's handbook instead, not this manual.

FAQ

Q: Is this a searchable PDF, and can I read the wiring diagrams clearly?

A: Yes, it's a PDF you can search, and the wiring diagrams are meant to be zoomed in on a screen or printed.

Q: How do I know if it fits my exact 325 machine?

A: Check your serial plate. If your 325 is in the 511820001-511899999 range, this is the right manual.

Q: Is this the right document if I'm doing full repairs, not just oil changes?

A: Yes, this is the workshop service manual, the one you use for real diagnosis and teardown work.

If your 325's serial number falls in that range and you're actually turning wrenches on it, this is the one you want. If the serial doesn't match, don't buy it.

📘 Show Index

Table of Contents:

  • MAINTENANCE SAFETY
  • ALPHABETICAL INDEX
  • FOREWORD
  • CONTENTS
    • SAFETY INSTRUCTIONS
    • HYDRAULIC EXCAVATOR SERIAL NUMBER
    • ENGINE SERIAL NUMBER
    • DELIVERY REPORT
    • HYDRAULIC EXCAVATOR IDENTIFICATION
  • PREVENTIVE MAINTENANCE
    • SERVICE SCHEDULE
    • ENGINE COVER
      • Procedure
    • AIR CLEANER SERVICE
      • Replacing The Filter Element
    • FUEL SYSTEM
      • Fuel Specification
      • Fuel System Service
      • Fuel Filter
      • Maintenance
      • Removal And Installation
      • Removing Air From The Fuel System
    • ENGINE LUBRICATION SYSTEM
      • Checking The Engine Oil
      • Engine Oil And Filter Replacement
    • COOLING SYSTEM
      • Coolant Level
      • Coolant Replacement
    • HYDRAULIC SYSTEM
      • Checking And Adding Fluid
      • Replacement Of The Hydraulic Filter
      • Hydraulic Reservoir
    • USING A BOOSTER BATTERY (Jump Starting)
      • Procedure
    • LUBRICATION OF THE HYDRAULIC EXCAVATOR
      • Procedure
    • FINAL DRIVE CASE
      • Checking Oil Level
      • Draining Final Drive Case
  • HYDRAULIC SECTION
    • HYDRAULIC SCHEMATIC
    • HYDRAULIC SERVICE INFORMATION
      • Checking The Main Relief Valve
      • Checking The Hydraulic Pump
      • Removal And Installation
      • Parts Identification (S/N 51182001 – 511820408)
      • Disassembly And Assembly (S/N 511820001–511820408)
      • Parts Identification (S/N 511820409 & Above)
      • Disassembly (S/N 511820409 & Above)
      • Assembly (S/N 511820409 & Above)
    • HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511820001–511820519)
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Inlet Section (R.H. and L.H. Travel)
        • Disassembly
        • Assembly
      • Valve Sections (Boom, Bucket & Arm)
        • Disassembly
        • Assembly
      • Valve Sections (Auxiliary)
        • Disassembly
        • Assembly
      • Port Relief Valve
        • Disassembly
        • Assembly
        • Adjustment
      • Main Relief Valve
        • Disassembly
        • Assembly
        • Adjustment
    • HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511820001–511820519)
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Inlet Section (Housing Swing)
        • Disassembly
        • Assembly
      • End Cover (Boom Swing) And Valve Section (Blade)
        • Disassembly
        • Assembly
      • Load Check Block
        • Disassembly
        • Assembly
      • Build–up Valve
        • Disassembly
        • Assembly
        • Disassembly
        • Assembly
        • Adjustment
    • HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE (S/N 511820520 & Above)
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Inlet Section Disassembly And Assembly
      • Right Hand And Left Hand Travel Section
        • Disassembly
        • Assembly
      • Boom, Bucket And Arm Section
        • Disassembly
        • Assembly
      • Auxiliary Valve Section
        • Disassembly
        • Assembly
    • PORT RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above)
      • Parts Identification
      • Disassembly
      • Assembly
      • Adjustment
    • MAIN RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above)
      • Parts Identification
      • Disassembly
      • Assembly
      • Adjusting The Main Relief Valves
    • HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511820520 & Above)
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Blade And Boom Swing Section
        • Disassembly
        • Assembly
      • Lockout Valve Disassembly
      • Lockout Valve Assembly
      • Swing Motor Section
        • Disassembly
        • Assembly
      • Build Up Valve Disassembly
      • Build Up Valve Assembly
      • Build Up Valve Test Procedure
    • ACCUMULATOR
      • Pressure Reducing Valve
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
      • Setting The Safety Relief Valve
      • Charging
    • PORT BLOCK
      • Removal And Installation
    • OIL COOLER
      • Removal And Installation
    • HYDRAULIC RESERVOIR
      • Removal And Installation
    • HYDRAULIC FILTER ASSEMBLY
      • Removal And Installation
    • BOOM CYLINDER
      • Removal And Installation
      • Boom Cylinder Shield
    • ARM CYLINDER
      • Removal And Installation
    • BUCKET CYLINDER
      • Removal And Installation
    • BLADE CYLINDER
      • Removal And Installation
    • BOOM SWING CYLINDER
      • Removal And Installation
    • HYDRAULIC CYLINDER
      • Disassembly
      • Assembly
    • JOYSTICK CONTROL CHANGE
  • DRIVE SECTION
    • LEFT CONSOLE
      • Lockout Valve Removal And Installation
      • Cylinder Removal And Installation
      • Removal And Installation
    • LEFT JOYSTICK
      • Removal And Installation
    • JOYSTICK
      • Disassembly And Assembly
    • CONTROL LEVERS
      • Removal And Installation
      • Speed Control Lever
      • Blade Lever
    • RIGHT CONSOLE
      • Removal And Installation
    • RIGHT JOYSTICK
      • Removal And Installation
    • FOOT PEDALS AND STEERING LEVERS
      • Removal And Installation
      • Bushing Removal And Installation
  • UPPER WORKS AND SWING SECTION
    • ENGINE COVER
      • Removal And Installation
    • SEAT AND MOUNTING FRAME
      • Removal And Installation
    • CENTER FLOOR PANEL
      • Removal And Installation
    • SWING MOTOR COVER
      • Removal And Installation
    • REAR FLOOR PANEL
      • Removal And Installation
    • INSPECTION COVER
      • Removal And Installation
    • TOOL BOX
      • Removal And Installation
    • LEFT HAND SIDE COVER
      • Removal And Installation
    • CORNER POST
      • Removal And Installation
    • COUNTERWEIGHTS
      • Removal And Installation
    • FRONT ENGINE COVER
      • Removal And Installation
    • FUEL TANK
      • Removal And Installation
    • BUCKET
      • Removal And Installation
    • BUCKET TEETH
      • Removal And Installation
    • ARM
      • Removal And Installation
    • BOOM
      • Removal And Installation
    • BOOM SWING BRACKET
      • Removal And Installation
      • Replacing Boom Swing Bracket Bushings
    • SWING MOTOR
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CROSS PORT RELIEF VALVE (S/N 511820001–511820519)
      • Disassembly
      • Assembly
      • Description
    • COUNTER BALANCE VALVE (S/N 511820520 &Above)
      • Removal And Installation
      • Disassembly
      • Assembly
    • SWING GEAR BOX ASSEMBLY
      • Parts Identification
      • Disassembly
      • Assembly
    • UPPERSTRUCTURE AND SWING CIRCLE GEAR
      • Removal And Installation
      • Swing Bearing Removal
      • Swing Bearing Installation
      • Alignment Pins (Threaded)
      • Alignment Pins (Not Threaded)
    • CENTER SWIVEL JOINT
      • Removal And Installation (Through Upper Access Cover)
      • Removal And Installation (Through Bottom Access Cover)
      • Parts Identification (S/N 511820001–511820197)
      • Parts Identification (S/N 511820198 & Above)
      • Description
      • Disassembly (S/N 511820198 & Above)
      • Assembly (S/N 511820198 & Above)
    • ROPS CANOPY
      • Removal And Installation
    • CAB
      • Removal And Installation
      • Door Removal And Installation
      • Front Window Removal And Installation
      • Front Lower Glass Removal And Installation
      • Front Upper Plexiglass Removal And Installation
      • Door Glass Removal And Installation
      • Left Hand Side Glass Removal And Installation
      • Rear Glass Removal And Installation
      • Right Hand Side Glass Removal And Installation
    • CAB/CANOPY REAR COVER
      • Removal And Installation
  • MAIN FRAME AND TRACKS
    • BLADE
      • Removal And Installation
    • TRACK
      • Track Tension Adjustment
      • Rubber Tracks
      • Steel Tracks
      • Removal And Installation
    • TRACK FRAME
      • Disassembly And Assembly
    • TRACK IDLER
      • Parts Identification
      • Disassembly
      • Assembly
    • TRACK ROLLER
      • Parts Identification
      • Disassembly
      • Assembly
    • FINAL DRIVE
      • Removal And Installation
      • Parts Identification
    • FINAL DRIVE
      • Parts Identification
    • TRAVEL MOTOR
      • Disassembly
      • Assembly
    • FINAL DRIVE CASE
      • Check Oil Level
      • Draining Final Drive Case
    • TRACK
      • Damage Identification And Causes
  • ELECTRICAL SYSTEM
    • ELECTRICAL SCHEMATICS
    • TROUBLESHOOTING
    • ELECTRICAL SYSTEM
      • Description
      • Fuses
      • Electrical System Service
    • BATTERY (S/N 20001–20294)
      • Checking The Battery
      • Removal And Installation
    • BATTERY(S/N 20295 and up)
      • Checking The Battery
      • Removal And Installation
    • ALTERNATOR
      • Belt Adjustment
      • Removal And Installation
    • STARTER
      • Removal And Installation
      • Disassembly And Assembly
      • Cleaning And Inspection
    • FUEL LEVEL SENDER
      • Removal And Installation
      • Checking
    • INSTRUMENT PANEL
      • Removal And Installation
    • CAB ELECTRICAL (Cab Option)
  • ENGINE SERVICE
    • TROUBLESHOOTING
    • VALVE CLEARANCE
      • Adjustment
    • ENGINE COMPRESSION
      • Checking
    • ELECTRIC FUEL PUMP
      • Remove Air From The Fuel System
      • Removal And Installation
    • FUEL FILTER
      • Removal And Installation
    • FUEL INJECTION PUMP
      • Checking The Injection Pump
      • Removal And Installation
      • Timing The Injection Pump
    • FUEL INJECTOR NOZZLES
      • Removal And Installation
      • Checking The Injector Nozzle
    • GLOW PLUGS
      • Removal And Installation
      • Checking The Glow Plug
    • RADIATOR
      • Removal And Installation
    • MUFFLER
      • Removal And Installation
    • AIR CLEANER
      • Removal And Installation
    • ENGINE
      • Removal And Installation
    • ENGINE FLYWHEEL
      • Removal And Installation
      • Flywheel Ring Gear
    • CYLINDER HEAD
      • Removal
      • Disassembly Of The Cylinder Head
      • Servicing The Cylinder Head And Valves
      • Checking Valve Springs
      • Checking Rocker Arm And Shaft
      • Assembling The Cylinder Head
      • Installing The Cylinder Head
    • TIMING GEAR COVER
      • Removal And Installation
    • TIMING GEAR, CAMSHAFT AND OIL PUMP
      • Removal And Installation
      • Oil Pump Service
      • Servicing The Camshaft
    • CRANKSHAFT & PISTONS
      • Removal And Installation
      • Crankshaft Service
      • Servicing The Connecting Rods And Pistons
      • Checking The Cylinder Liners
      • Cylinder Liner Installation
    • WATER PUMP
      • Removal And Installation
      • Disassembly And Assembly
  • SPECIFICATIONS
    • EXCAVATOR SPECIFICATIONS
      • Machine Dimensions
      • Lifting Capacity
      • PERFORMANCE & OPERATION
      • ENGINE
      • HYDRAULIC SYSTEM
      • SWING SYSTEM
      • HYDRAULIC CYLINDERS
      • CYLINDER CYCLE TIMES
      • DRIVE SYSTEM
      • BRAKES
      • UNDERCARRIAGE
      • TRACK
      • CAPACITIES
      • DIGGING FORCE
    • ENGINE SPECIFICATIONS
      • Fuel Injection Nozzles
      • Fuel Injection Pump
      • Cylinder Head
      • Valves
      • Valve Springs
      • Rocker Arms
      • Camshaft
      • Cylinders
      • Piston Rings
      • Pistons
      • Crankshaft
      • Oil Pump
      • Engine Oil
      • Specifications
      • ENGINE BOLT TORQUE
    • FUEL, COOLANT AND LUBRICANTS
      • CHART
    • ENGINE OIL SPECIFICATIONS
      • Description
      • Ethylene Glycol
      • Propylene Glycol
    • Re–Grinding The Crankshaft
    • BUCKET SPECIFICATIONS
    • DECIMAL AND MILLIMETER EQUIVALENTS
    • U.S. TO METRIC CONVERSION
  • SERVICE MANUAL REVISION
    • 325-1
    • 325-2
    • 325-3
    • 325-4

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